Mating cover for expandable baton

ABSTRACT

A cover for an expandable baton handle is injection molded onto the handle to provide an integral, unitary handle cover for the baton handle. The baton handle is further provided with locking rings or grooves at opposite ends. The grooves cooperate with ridges provided on the cover in a mating relationship to prevent the cover from moving relative to the baton handle.

RELATED APPLICATIONS

[0001] This is a continuation-in-part application of U.S. patentapplication Ser. No. 08/716,085, filed on Sep. 19, 1996, still pending,which is a continuation-in-part application of U.S. patent applicationSer. No. 08/410,764, filed on Mar. 27, 1995, now U.S. Pat. No.5,645,276.

BACKGROUND OF INVENTION

[0002] 1. Field of Invention

[0003] This invention is directed generally to expandable batons for useby law enforcement personnel and is specifically directed to a formedhandle cover for such batons.

[0004] 2. Description of the Prior Art

[0005] Expandable batons are well known intermediate force weapons usedas a restraint device by law enforcement personnel. Typically, suchbatons include a plurality of nesting sections which may be whipped andtelescoped into the expanded position and locked in place in a singlemotion. The locking mechanism may include a button lock system as shownin my issued U.S. Pat. No. 5,149,092, or a tapered wedge lock system asshown in my U.S. Pat. No. 5,348,297.

[0006] The largest section of the nesting baton typically defines thehandle by which the baton is gripped during use. It is desirable thatthe handle be covered with a high-friction cover in order to permitmaximum utilization of the baton while minimizing the risk of the batonslipping out of the grasp of the user. The material for the cover mustbe capable of withstanding rigorous, repeated use without separatingfrom the baton handle. In the prior art, several different cover stylesand designs are available, ranging from a knurled surface applieddirectly to the baton casing to wrapping or enveloping the baton handlewith a Neoprene brand, Hypolon brand or foamed vinyl cover.

[0007] The knurled handle increases the friction over a smooth surface,but not to a degree sufficient to achieve the desired functional result.That is, the friction level of the cover is still too low for certainwhipping motions, increasing the risk of the baton flying out of thehand during use. Alternatively, too much knurling may eat throughclothing or wear the lining of a coat or shirt. However, the knurledhandle does meet the requirements of being durable and permanentlysecured to the baton, thereby minimizing loss of function through wearand tear.

[0008] As more exotic materials are utilized for batons, from woundfibers to hardened steel or tungsten/magnesium alloys, the cost ofmachining a knurled handle becomes almost prohibitive.

[0009] More recently, handles are covered with a cylindrical tube coverformed to fit snugly on the periphery of the baton. Specifically, covershave been dip molded onto cores shaped like baton handles. Dip moldedcovers, however, are time consuming and expensive to manufacture.Further, as a result of the dipping process, the wall of the cover isthicker at its bottom portion than at its top portion. To protect thethinner portion of the cover, a collar is welded into the handle. Suchcollars, however, are expensive and add to the cost of manufacturing thebaton. Also, dip molding is imprecise.

[0010] Environmental factors such as heat, temperature and humidity havea great effect on the thickness of the covers. Thus, it is not uncommonfor dip molded covers to be rejected as being either too thick or toothin.

[0011] The covers are bonded to the baton by either glue or otherbonding adhesives which are applied directly to the abutting surfaces orthrough the use of double backed tape or the like. Double backed tape isparticularly useful since it allows the best available bonding agent tobe applied directly to the cover while at the same time permitting useof the most effective bonding agent to be applied against the surface ofthe handle.

[0012] However, even with the use of double backed tapes, after repeateduses the cover will slip relative to the baton handle. As a result, thefront exposed edge of the cover tends to wear and roll back fromrepeated insertion of the baton into a typical scabbard used for stowingthe baton handle on the person of the law enforcement personnel. This isparticularly true if the baton includes an integral taper, making atubular cover loose in specific regions of the handle. Also, becauseinstalling the cover onto the handle must be done by hand, it requires agreat deal of time, which adds to the expense of the manufacturingprocess.

[0013] In addition, in practice the baton is extended by a whippingaction that causes the telescoping sections of the baton to lock in anextended position. After use, the extended baton must be retracted. Toretract the baton, the tip of the baton typically is struck against ahard surface and the telescoping sections collapse into a nestingposition within the baton handle. The collapsing action often requires asignificant force to release the extended baton from its locked extendedposition. The repeated action of extending and retracting the baton maycause the cover to slip relative to the baton. During the whippingaction used to extend the baton, there exists a potential for the coverto slip relative to the handle. Similarly, during the collapsing of thebaton, the striking action results in a downward force being applied tothe cover, the force having a tendency to cause the cover to sliprelative to the handle. The cover slipping relative to the handle canbring about undesirable results. For example, when the cover becomesloose relative to the baton handle, it is possible that the handle mayactually slip out of the cover during the extending action. Thus, thereis a need to provide an extendable baton having a cover that will notslip relative to the baton handle during use.

[0014] Rigid annular collars have helped alleviate this problem, butsuch collars increase both the cost of material and the cost of assemblyof the baton. In addition, it is possible that such collars willseparate from the baton, further increasing the possibility of reducingthe functional life of the device.

[0015] Because of the critical applications in which such batons areemployed, it is important that the handle cover be secure and maintainedat optimum function throughout its life. Therefore, there remains a needfor a durable friction cover for expandable batons designed for lawenforcement use.

SUMMARY OF THE INVENTION

[0016] The subject invention is specifically directed to a durablefriction cover for an expandable baton for law enforcement use. In apreferred embodiment of the invention, a cover is formed on and bondeddirectly to the handle of the expandable baton in an injection moldingoperation. This eliminates loose outer ends and resultant rolling ortearing of the cover through repeated use, without the need of a collarto protect the front exposed edge of the cover. The resulting cover isdurable, is permanently bonded to the baton and is inexpensive tomanufacture, the forming and bonding steps being accomplished in asingle overmolding process.

[0017] In the preferred embodiment, the baton handle is placed in a moldcavity and the cover material is injection molded directly onto thehandle. In an alternate preferred embodiment, the outer surface of thebaton handle is provided with circumferential locking rings or grooves.The material injection molded about the baton handle fills the lockinggrooves during the injection molding process such that there is a matingrelationship between the grooves of the baton handle and the resultinginjection molded cover. In particular, ridges are formed about theinside surface of the cover to mate with the grooves of the handle. Theridges of the cover and the grooves of the handle cooperate to retainthe cover in place after the cover is injection molded onto the batonhandle. The grooves are designed to prevent the cover from slipping ormoving relative to the baton handle during the extending or retractingactions. Furthermore, because the grooves are deeper than the “stretch”of the cover material, the ridges of the cover are prevented fromstretching out of cooperation with the grooves during the extension orretraction of the expandable baton. In this manner, the cover ismaintained in a fixed position with respect to the baton handle, therebypreventing the problems associated with slippage of the cover relativeto the baton handle. Furthermore, not only does injection moldingpermanently bond the material to the baton handle, but the mold cavitydefines the custom shape of the cover, permitting an integral,continuous, wrap around construction, greatly enhancing both theappearance and the durability of the cover. In addition, the moldingprocess eliminates several steps of manufacture, reducing the overallcosts of the product. Costs are further reduced because the moldingprocess ensures the precision of the covers, thereby reducing wasteresulting from imprecise covers.

[0018] Overmolding in this manner also permits a broader selection ofcovers to be utilized without changing the manufacturing process.Various pigments may be added to the stock material to permit handles ofdifferent, selected colors. The composition of the stock material andthe pressure and cure time of the molding process may be adjusted toprovide handles ranging from a hard, rigid material to a soft,compressible or resilient cover. The outer surface of the cover may becontrolled by the mold cavity surface.

[0019] The molded and formed cover of the subject invention greatlyimproves the function and appearance of the handle while at the sametime reducing the costs of the finished baton.

[0020] It is, therefore, an object and feature of the subject inventionto provide a formed cover for the handle of an expandable baton for lawenforcement use.

[0021] It is an additional object and feature of the subject inventionto provide a cover that is permanently bonded to the baton handle.

[0022] It is a further object and feature of the subject invention toprovide a cover and a baton handle wherein circumferential locking ringsor grooves are provided on the baton handle to mate with ridges providedon the cover to prevent relative movement between the cover and batonhandle during operation.

[0023] It is another object and feature of the subject invention toprovide a cover having outer ends which do not come loose or roll backas a result of repeated insertions of the baton into a standard batonscabbard on the person of the law enforcement personnel for stowing thebaton.

[0024] It is yet another object and feature of the subject invention toprovide a baton having a variety of color covers and texture coversusing a single manufacturing process.

[0025] Other objects and features of the invention will be readilyapparent from the following drawings and detailed description of thepreferred embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

[0026]FIG. 1 is a longitudinal view of a standard handle of anexpandable baton, prior to machining.

[0027]FIG. 2 is a longitudinal view of the baton handle of FIG. 1, aftermachining and swaging to form the finished handle.

[0028]FIG. 3 is a longitudinal view of the handle of FIG. 2 with theformed, molded cover, handle and end cap assembly.

[0029]FIG. 4 is an end view of the handle of FIG. 3.

[0030]FIG. 5 is a partial sectional view taken along line 5-5 of FIG. 4to show the detail of the molded cover with a lip molded adjacent theend of the cover.

[0031]FIG. 6 is a perspective, partial sectional view taken along line5-5 of FIG. 4 to show the detail of the molded cover without a lipmolded adjacent the end of the cover.

[0032]FIG. 7 is a perspective view of a baton handle havingcircumferential locking rings or grooves, a cover having ridges inmating relationship with the grooves, and an end cap assembly.

[0033]FIG. 8 is a longitudinal, partial sectional view of the embodimentof FIG. 7.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0034] A typical tube blank for defining the handle of an expandablebaton is shown in FIG. 1. The handle shown is of the type utilized inthe friction lock baton shown and described in my U.S. Pat. No.5,348,297, incorporated by reference herein. The baton handle 10includes a hollow, cylindrical tube 12 that is adapted to receive andnest additional sections of the baton. In a preferred embodiment, thehandle is 7.187 inches in length with an external diameter of 0.875inches, and is made of 14 gauge steel tubing. The ends 14 and 16 arechamfered typically at 45 degrees. As shown in FIG. 2, one end 14 of thetube is swedged approximately 0.875 inches to form a reducing interiortaper 18. This interior taper forms the handle of the wedge lock systemas described in my aforementioned U.S. Pat. No. 5,348,297. The outermostend 20 is bored to provide an enlarged annular recess for receiving andseating the periphery of the button end of the baton, also as shown inmy aforementioned U.S. Pat. No. 5,149,092. The opposite end 16 of thetube is externally threaded at 21 for receiving an end cap 23 (FIG. 3)in order to hold the assembled nested baton sections in place.

[0035] It will be noted that the machined area 20 and swedged area 18present unique problems for a cover to be placed over the tube in orderto provide a good friction cover. Specifically, tubular material will besomewhat loose at the swedged area in relationship to the remainder ofthe tube. Also, the exposed metal in the bore area 20 will generate anundesirable “clicking” sound when the button tip seats in the annularrecess. In the past, this has been resolved by placing an annular ringor collar over the end 14, increasing both material and assembly costs.

[0036] The reduced diameter of the swedged section 18 can only be dealtwith by utilizing a custom form cover instead of a standard straightcylindrical tube cover, greatly increasing the cost of the cover. In theprior art, a straight cylindrical tubular cover was generally utilizedwith a bonding agent between the cover and the steel tube. Whilegenerally suitable, the end of the cover adjacent outer end 14 of thetube would tend to roll up, particularly since the cover was slightlyoversize due to the swedged area 18.

[0037] In a preferred embodiment, the machined and swedged handle isplaced in a mold cavity and the cover 22 (see FIGS. 3, 4, 5) isinjection molded around the handle. This permits the cover 22 to betightly and permanently bonded not only to the straight section of thetube 12, but also to the swedged, tapered section 18, as well. As isshown in FIG. 5, the outer end 24 of the cover may be formed to enclosethe exposed outer end 14 of the handle to serve as a cushion for thebaton tip. Furthermore, as is shown in FIG. 5, the outer end 24 of thecover may continue into the annular recess 20, as shown at 26, therebyeliminating the necessity of an end cap. The molded cover 22 provides anintegral cover form fitted to the contours of the handle, covering allexposed areas where metal-to-metal contact is not desired. In addition,the integral cover eliminates any roll up tendencies previously due toloose fitting areas around the swedged portion.

[0038] The specific finish texture of the outer wall of the cover 22 iscontrolled by the surface of the mold cavity. Hardness of the cover iscontrolled by mold pressure, cure time and composition of the material.The cover color of the mold may be altered by providing pigmentation inthe material composition which is injected into the mold.

[0039] In a preferred embodiment, and as shown in FIG. 2, the outersurface of tube may be knurled or otherwise roughened as at 28 toprovide a better gripping or bonding surface for the cover 22. While theentire length of the tube 12 is knurled in the embodiment shown, goodenhanced bonding may be achieved with knurling only at or near thethreaded end 21 of the tube. This is because the wrapping of the cover22 at 26 provides a good bond at the opposite end.

[0040] An alternate preferred embodiment of the present invention isshown in FIGS. 7 and 8. In this embodiment, baton handle 110 includes ahollow, cylindrical tube 112 having ends 114, 116. The tube 112 issubstantially identical to tube 12 of the embodiment of FIGS. 1-5.Alternately, the tube 112 could have a taperless exterior. The tube 112in FIG. 7 differs from tube 12 in FIG. 1 in that tube 112 is providedwith a plurality of circumferential locking rings or grooves 119adjacent to each end 114, 116. The grooves 119 are formed in the tube112 by machining or any such suitable method. As in the embodiment ofFIGS. 1-5, one end 116 of tube 112 is externally threaded (not shown)for receiving an end cap 123 in order to hold the assembled nested batonsections in place.

[0041] The baton handle 110 of FIGS. 7 and 8 is further provided with acover 122. After the grooves are machined onto tube 112, a cover 122 isinjection molded directly onto the handle 110. As a result, the moldedcover 122 is attached to the tube 112 and provides an integral coverform fitted to the contours of the handle 110. Specifically, ridges 124are formed about the inside surface of the cover 122 to mate with thegrooves 119 of the handle 110. The mating relationship between thecircumferential grooves 119 and the ridges 124 functions to prevent thecover 122 from slipping or moving relative to the baton handle duringthe extending or retracting actions. Furthermore, because the grooves119 are deeper than the “stretch” of the cover material, the ridges 124of the cover 122 are prevented from stretching out of cooperation withthe grooves 119 during the extension or retraction of the expandablebaton.

[0042] As can be appreciated from FIGS. 7 and 8, the grooves 119 of tube112 provide a better gripping or bonding surface for the cover 122relative to the baton handle 110. It should be understood that thegrooves 119 provided on the tube 112 are not limited to the arrangementshown in FIGS. 7 and 8. Additional grooves can be provided at either endof the tube. Similarly, a fewer number of grooves at either end of thetube can be provided. It is possible to have grooves only at the end 116of tube 112. Also, the number of grooves at each end of the tube neednot be equal. Further, the dimensions of the grooves need not beidentical. Nonetheless, the particular arrangement of grooves shown inFIGS. 7 and 8 has been shown to be particularly effective in preventingrelative movement between the cover and the baton handle.

[0043] In a preferred embodiment, the grooves as shown in FIGS. 7 and 8are equally spaced and have a width in the range of 0.05-0.50 inches,preferably 0.080 inches, and a depth in the range of 0.02-0.05 inches,preferably 0.030 inches. Furthermore, the handle cover 122 is made of anelastomer having the trade name Santoprene available from AdvancedElastomer Systems. With this combination, the elastomeric cover 122 willnot stretch beyond the grooves 119 of the baton handle 110 duringextension or retraction of the expandable baton in operation. Thus, thecover 122 is permanently fixed to the handle 110 of the baton.

[0044] The interaction between grooves 119 and ridges 124 in combinationwith the cover 122 being injection molded directly onto the tube 112assist in keeping the cover in place. The cover 122 is prevented frommoving relative to the tube 112 whether the baton is being whipped intoits extended position or placed into its collapsed position. Thus, theundesirable wearing and rolling back of the front edge of the cover isavoided. In another preferred embodiment, a single groove having a widthof between 0.25 and 0.50 inches may be provided on the handle near theend opposite the tip.

[0045] While certain features and embodiments of the invention have beendescribed herein, it will be readily understood that the inventionencompasses all modifications and enhancements within the scope andspirit of the following claims.

1. A handle in combination with an expandable baton, the handlecomprising: a hollow cylindrical tube having at least one groove about aportion thereof; and a cover attached to the tube, the cover conformingto an outer surface of the tube; whereby the groove of the tubecooperates with the cover to prevent the cover from moving relative tothe tube.
 2. The handle of claim 1 wherein the cover is provided with atleast one ridge, the ridge mating with the corresponding groove of thetube to prevent the cover from moving relative to the tube.
 3. Thehandle of claim 1 wherein the cover is injection molded directly ontothe tube.
 4. The handle of claim 1 further provided with an end cap atone end of the tube.
 5. The handle of claim 1 wherein the groove ismachined into the tube.
 6. The handle of claim 1 wherein the tube has astraight section and a tapered section.
 7. A handle in combination withan expandable baton having at least one member telescopingly mounted inthe handle, wherein the telescoping member includes an enlarged outerend which is seated in the handle when the telescoping member is nestedin the handle, the handle comprising: a hollow cylindrical tube; a coverattached to the tube, the cover conforming to an outer surface of thetube; and means for preventing the cover from moving relative to thetube.
 8. The handle of claim 7 wherein the means for preventing thecover from moving relative to the tube comprises at least one grooveprovided circumferentially at one end of the tube.
 9. The handle ofclaim 8 wherein the means for preventing the cover from moving relativeto the tube further comprises at least one ridge provided on the coverfor mating with the groove.
 10. The handle of claim 7 wherein the meansfor preventing the cover from moving relative to the tube comprisesgrooves provided circumferentially about a portion of the tube.
 11. Thehandle of claim 10 wherein the means for preventing the cover frommoving relative to the tube further comprises ridges provided on thecover for mating with the grooves.
 12. The handle of claim 10 whereinthe grooves are provided at both ends of the tube.
 13. The handle ofclaim 10 wherein the grooves are machined into the tube.
 14. The handleof claim 7 wherein the cover is injection molded directly onto the tube.15. The handle of claim 7 further provided with an end cap at one end ofthe tube.
 16. The handle of claim 7 wherein the tube has a straightsection and a tapered section.
 17. A method of making a handle for abaton comprising the steps of: a) providing a hollow cylindrical tube;b) machining one or more grooves circumferentially about a portion ofthe tube; and c) injection molding a cover directly onto the tube. 18.The method of claim 17 wherein the machining step further comprisesmachining the grooves at one end of the tube.
 19. The method of claim 17wherein the machining step further comprises machining the grooves atopposite ends of the tube.
 20. The method of claim 17 wherein theinjection molding step further comprises providing the cover with one ormore ridges.